ZA14J (ZA45J)

Service and Maintenance Manual

Zoomlion Heavy Industry Science & Technology Co.Ltd.

Add：No.996 Tengfei Rd Wangcheng District Changsha Hunan P. R. China Zip Code:410200

E-mail:[email protected] Eel:400-800-0157

Open up the WeChat, Scan the QR code above; All rights reserved 2015©Zoomlion,reserves all rights,Without the written permission of Zoomlion, the contents of any part of this sample may not be copied for any purpose.
Service and Maintenance Manual

ZA14J (ZA45J)
Service and Maintenance Manual

Comply with ANSI SAIA_A92.20-2018 and CSA-B354.6-2017

Standard

2020.1 A
 Foreword
This Service and Maintenance Manual applies to the ZA14J aerial work platform (hereinafter referred to
as the AWP).

This manual describes proper inspection, servicing and maintenance. Users must fully understand and
apply the contents described in this manual to maximize the performance and ensure the long-term safe
and efficient use. This manual does not cover the use and maintenance of the engine. For details on
engine, please refer to the engine instruction manual.

The manual includes the structure and schematic diagram of the main components. If it is necessary to
repair and replace the components, the material code of the required replacement parts can be found in
Parts Manual.

This manual should be considered a permanent part of your machine and should remain the machine at
all times.

Do not repair the parts marked with professional maintenance. Zoomlion AWP Machinery Company
does not take the consequence for wrong maintenance.

Users must comply with the highest standards of safety first. Pay special attention to the safety control
device for regular inspection. Do not operate the machine when the safety device fails or working
abnormally. Do not modify the structure or add additional parts for more functions. Otherwise, you will
be responsible for any personal injury or damage caused by the unauthorized modification.

The warranty period for the aerial work platform is as specified in this Service and Maintenance Manual.
When maintenance is required, our company provides on-site service or please go to our service center
for maintenance.

Our company reserves the right to continually revise the contents of this manual with technical
improvements. Any changes are subject to change without notice. Some of the pictures in this manual
may not match the actual product due to design improvement, etc., but it does not affect your use. The
product status is subject to the actual product.

I
 Foreword

Symbols and their description:

Danger indicates an imminently dangerous situation. If not avoided, will result in death or serious
injury.

Warning indicates a potential hazardous situation. If not avoided, will result in death or serious injury.

Caution indicates a potential hazardous situation. If not avoided, will result in minor or moderate injury.

Notice indicates information of property and device damage, or wrong operation. If not avoided, could
result in property loss, damage to machine parts or reduced mechanical properties.

Used to indicate or add additional information to individual information.

Indicates that this operation does not comply with safety regulations and is prohibited or prone to
casualties.

II
 Contents
Foreword................................................................................................................................................... I
Content................................................................................................................................................... III

SECTION 1 MAINTENANCE SAFETY INSTRUCTION ............................................................ 1-1

1.1 Maintenance Personnel Duties, Requirements and Safety Equipment ............................................. 1-1
1.1.1 Duties .............................................................................................................................. 1-1
1.1.2 Basic requirements.......................................................................................................... 1-1
1.1.3 Personnel safety equipment ............................................................................................ 1-1
1.2 Maintenance Precautions .................................................................................................................. 1-2
1.2.1 Precautions...................................................................................................................... 1-2
1.2.2 Precautions in maintenance ............................................................................................ 1-3

SECTION 2 TECHNICAL PARAMETERS ...................................................................................... 2-1

2.1 Performance ...................................................................................................................................... 2-1
2.2 Specification and Performance ......................................................................................................... 2-1
2.3 Capacity ............................................................................................................................................ 2-2
2.4 Components Specification ................................................................................................................ 2-2
2.4.1 Engine ............................................................................................................................. 2-2
2.4.2 Battery ............................................................................................................................ 2-3
2.5 Tire .................................................................................................................................................... 2-3
2.6 Functional Speed............................................................................................................................... 2-4
2.6.1 Operating procedure when testing speed ........................................................................ 2-4
2.6.2 Test cautions ................................................................................................................... 2-4
2.7 Torque Requirements ........................................................................................................................ 2-5
2.8 Lubrication ........................................................................................................................................ 2-5
2.8.1 Hydraulic oil ................................................................................................................... 2-5
2.9 Pressure Setting................................................................................................................................. 2-6

SECTION 3 GENERAL INTRODUCTION ...................................................................................... 3-1

3.1 Machine Preparation, Inspection and Maintenance .......................................................................... 3-1
3.1.1 General introduction ....................................................................................................... 3-1
3.1.2 Preparation, Inspection and Maintenance ....................................................................... 3-1
3.1.3 Pre-delivery and daily inspection ................................................................................... 3-1
3.1.4 Machine annual inspection ............................................................................................. 3-1
3.1.5 Preventive maintenance .................................................................................................. 3-2

III
 Contents
3.2 Maintenance and Service Instruction ................................................................................................ 3-2
3.2.1 General instruction.......................................................................................................... 3-2
3.2.2 Safety and operating standards ....................................................................................... 3-3
3.2.3 Cleaning .......................................................................................................................... 3-3
3.2.4 Component disassembly and installation ........................................................................ 3-3
3.2.5 Component disassembly and reinstallation ..................................................................... 3-3
3.2.6 Pressure-fit parts ............................................................................................................. 3-3
3.2.7 Bearing............................................................................................................................ 3-3
3.2.8 Washer ............................................................................................................................ 3-4
3.2.9 Bolt and torque applications ........................................................................................... 3-4
3.2.10 Hydraulic line and electric wiring................................................................................. 3-4
3.2.11 Hydraulic system .......................................................................................................... 3-4
3.2.12 Lubrication.................................................................................................................... 3-4
3.2.13 Battery .......................................................................................................................... 3-4
3.2.14 Lubrication and maintenance ........................................................................................ 3-5
3.3 Lubrication and Information ............................................................................................................. 3-5
3.3.1 Hydraulic system ............................................................................................................ 3-5
3.3.2 Hydraulic oil ................................................................................................................... 3-5
3.3.3 Hydraulic oil replacement............................................................................................... 3-7
3.3.4 Lubrication specification ................................................................................................ 3-7
3.4 Cylinder Drift Test ............................................................................................................................ 3-7
3.4.1 Platform drift .................................................................................................................. 3-7
3.4.2 Cylinder drift .................................................................................................................. 3-8
3.5 Pin and Bearing Inspection Instruction ............................................................................................. 3-9
3.5.1 Fiber bearing ................................................................................................................... 3-9
3.6 Welding on the Device ...................................................................................................................... 3-9
3.6.1 Perform the following operations when welding on the device ...................................... 3-9
3.6.2 Not perform the following operations when welding on the device ............................... 3-9
3.7 Use Insulating Grease in Electrical Connection Location .............................................................. 3-10
3.8 Engine Electrical System Maintenance........................................................................................... 3-10

SECTION 4 CHASSIS AND TURNTABLE....................................................................................... 4-1

4.1 Tire and Wheel .................................................................................................................................. 4-1
4.1.1 Tire inflation ................................................................................................................... 4-1
4.1.2 Tire damage .................................................................................................................... 4-1

IV
 Contents
4.1.3 Tire replacement ............................................................................................................. 4-2
4.1.4 Wheel replacement ......................................................................................................... 4-2
4.1.5 Wheel installation ........................................................................................................... 4-2
4.2 Swing Axle Exhaust and Locking Test ............................................................................................. 4-3
4.2.1 Floating cylinder exhaust ................................................................................................ 4-3
4.2.2 Swing axle lock test ........................................................................................................ 4-4
4.3 Chassis Angle Sensor System ........................................................................................................... 4-5
4.4 Auxiliary Power System ................................................................................................................... 4-5
4.5 Oscillating axle system ..................................................................................................................... 4-5
4.6 Traveling Drive system ..................................................................................................................... 4-6
4.7 Travel Reducer .................................................................................................................................. 4-7
4.7.1 Disassembly .................................................................................................................... 4-7
4.7.2 Installation ...................................................................................................................... 4-8
4.8 Traveling Motor ................................................................................................................................ 4-9
4.8.1 Disassembly .................................................................................................................... 4-9
4.8.2 Installation ...................................................................................................................... 4-9
4.9 Generator ........................................................................................................................................ 4-10

SECTION 5 BOOM AND PLATFORM ............................................................................................. 5-1

5.1 Platform and Jib ................................................................................................................................ 5-1
5.1.1 Load cell disassembly ..................................................................................................... 5-1
5.1.2 Rotary actuator disassembly ........................................................................................... 5-2
5.1.3 Jib lifting cylinder ........................................................................................................... 5-2
5.2 Boom Assembly ................................................................................................................................ 5-3
5.2.1 Cable disassembly .......................................................................................................... 5-4
5.2.2 Upper cylincer disassembly ............................................................................................ 5-5
5.2.3 Lower leveling cylinder and lifting cylinder .................................................................. 5-6
5.2.4 Upper boom disassembly ................................................................................................ 5-7
5.2.5 Telescopic cylinder disassembly ..................................................................................... 5-9
5.2.6 Tower boom and its cylinder disassembly .................................................................... 5-10

SECTION 6 ELECTRICAL SYSTEM MAINTENANCE ............................................................... 6-1

6.1 Fault Code ......................................................................................................................................... 6-1
6.2 Common Faults and Solutions .......................................................................................................... 6-5

V
 Contents
SECTION 7 ELECTRICAL INFORMATION AND SCHEMATIC ............................................... 7-1
7.1 General Introduction ......................................................................................................................... 7-1
7.2 Multimeter Basic Operation .............................................................................................................. 7-1
7.2.1 Grounding ....................................................................................................................... 7-1
7.2.2 Backside detection .......................................................................................................... 7-1
7.2.3 Minimum value/maximum value .................................................................................... 7-1
7.2.4 Polarity............................................................................................................................ 7-1
7.2.5 Range .............................................................................................................................. 7-2
7.2.6 Voltage measurement ...................................................................................................... 7-2
7.2.7 Resistence measurement ................................................................................................. 7-2
7.2.8 Conduction measurement ............................................................................................... 7-3
7.2.9 Current measurement ...................................................................................................... 7-3
7.3 DEUTSCH Connector ...................................................................................................................... 7-4
7.3.1 DT/DTP series connector assembly ................................................................................ 7-4
7.3.2 DT/DTP series connector disassembly ........................................................................... 7-5
7.3.3 HD30/HDP20 series connector assembly ....................................................................... 7-5
7.3.4 HD30/HDP20 series connector disassembly .................................................................. 7-6
7.4 Electrical Schematics ........................................................................................................................ 7-8
7.5 Hydraulic Schematics ..................................................................................................................... 7-14

VI
 SECTION ONE MAINTENANCE SAFETY INSTRUCTION

1.1 Maintenance Personnel Duties, Requirements and Safety Equipment

1.1.1Duties
The maintenance personnel must maintain the aerial work platform and to be responsible for the safe
use and normal operation. The Maintenance and Service Manual provided by the company shall be
observed and all necessary maintenance shall be carried out under the safe working system.

1.1.2 Basic requirements

Maintenance personnel should meet the following conditions:
a) Inspectors and maintenance personnel should have appropriate qualifications or authorization;
b) Experienced technicians or professional engineers;
c) Familiar with the aerial work platforms maintenance and the potential danger;
d) Received appropriate education and training, including courses related to the use of special
equipment;
e) Familiar with the relevant maintenance procedures and safety precautions of aerial work platforms.

1. Only the trained and qualified personnel who have obtained the qualification certificate can
repair the aerial work platform;

2. Do not perform any maintenance when you cannot work properly after being unwell, drinking
or taking medicine.

1.1.3 Personnel safety equipment

a) The operator must use safety equipment when operating the machine;
b) Select suitable safety equipment such as helmets, gloves, protective goggles, safety belts, boots and
hearing protection devices according to the work site conditions;

Figure 1-1 Personnel safety equipment

1-1
c) Check safety equipment before and after work, perform maintenance according to specified
procedures or replacement if necessary;
d) Keep inspection and maintenance records if needed;
e) Certain safety equipment (such as helmets and seat belts) might be damaged after prolonged use
and should be inspected and replaced periodically.

1. Inspect safety equipment regularly, replace damaged parts if necessary;

2. All personal protective equipment does not provide 100% protection;

3. Please wear protective gear properly and be familiar with the various hazards that may be
encountered during the operation for safety consideration;

4. Periodic maintenance and repair must be carried out by professional maintenance personnel.

Inspection or maintenance in a space-constrained, poorly ventilated location may result in

poisoning.

1.2 Maintenance Precautions

1.2.1 Precautions
a) Ventilation;
Ventilation is required when starting the engine in a space-constrained site. Connect a hose to the
exhaust pipe to discharge the smoke to the outside. Open the doors and windows to keep air flowing.
b) Clean up the work site;
Implementing the inspecting or maintaining works in a messy place may result in personal injury or a
fall accident. All obstacles should be removed before work.
c) Stop the engine before performing inspections or maintenance work.
Do not perform inspections or maintenance while the engine is running to prevent accidents;
Remove the key before inspection and maintenance, and place a No Operation warning sign on the door
or on the joystick of the control panel.

During inspection or maintenance, any unrelated personnel inadvertently start the engine, which
may cause mechanical damage or personal injury.

a) Inspection or maintenance must be carried out by at least 2 people while the engine is running. One

1-2
 of them must be in front of the turntable or platform control panel so that the engine can be shut
down at any time if necessary, and others can conduct inspection or maintenance. Personnel should
keep close contact to work safely;
b) Clean the aerial work platform before inspection or maintenance. The dust or debris on the aerial
work platform not only makes the faulty components or parts difficult to find, but also can be
mixed into the components or parts during operation. In addition, dust or mud can cause injury to
the eyes or make the floor slippery that results in injury;
c) When cleaning the machine with a high-pressure water gun, it is forbidden to directly align the
electrical control box and the connector, otherwise it will cause an electrical short circuit.

It is strictly forbidden to align water or water jets with electrical components! Otherwise there is
danger of electric shock!

Figure 1-2 Mind electric shock

1.2.2 Precautions in maintenance

a) Prevent fire.
1) Use non-flammable cleaning fluids for parts and components cleaning;
2) Store fuel and grease items away from flames or sparks;
3) No smoking;
4) Do not allow flames or sparks to get close to flammable objects;
5) Have a fire extinguisher and understand how to use it;
6) Use explosion-proof lights when checking fuel, oil and battery fluids;
7) Keep flammable objects away from flying sparks or molten metal during grinding or welding.
b) Only trained technicians could conduct welding and repairing for every part and wear-resistant
parts.

1-3
 Figure 1-3 Mind explosion

The positive and negative wires of the battery must be removed when welding to prevent the
positive and negative poles of the welder from forming a loop with the unit body, thereby burning
electrical components such as controllers and sensors. The company does not take the
consequences for wrong operation.

It is forbidden to use the machine as a ground wire during welding.

a) Check or maintain the machine after the temperature has been lowered;
Contact with the components might cause burn hazard, as the temperature of components goes high
when the machine is running. These components include engines, mufflers, engine cooling water,
radiators, hydraulic oil, reducers, hydraulic kits and hydraulic accessories. These components or parts
should be allowed to cool down before starting inspection or maintenance.

Figure 1-4 Mind burn hazard

b) Pay attention to the installed position of parts when unloading. Technicians performing the
installation must be familiar with each part to ensure proper installation.

1-4
It is strictly forbidden to disassemble electronic components.

a) Do not allow tools or parts to fall into the inspection hole; do not allow objects to fall into the holes
during work. Falling objects can damage the machine or cause the machine to malfunction. Any
tools or objects that fall into the inspection hole must be removed;
b) If electrical, circuit or hydraulic components (valves, pumps, etc.) need to be replaced, the replaced
parts should be checked and adjusted according to the data on the machine schematic.

Manufacturer-approved parts must be used, especially those that affect load bearing performance
and safety performance.

a) The components that affect the stability, strength and performance of the platform could be
modified only after obtaining the approval of the manufacturer, such as structural parts, carriers,
electrical components, and hydraulic components. Otherwise, any modifications to the aerial work
platform are prohibited;
b) Pay attention to high pressure oil; High pressure fuel or hydraulic oil can cause serious damage to
the skin or eyes. To avoid this danger, the following instructions should be followed:
1) The pressure inside the pipe must be released before disassembling the pipe;
2) Wear goggles and protective gloves when checking for leaks. Leakage of high pressure oil
may not be visible, use cardboard or wood chips to confirm oil leakage. DO NOT use your
hand to check for leaks.

Figure 1-5 Prevent burns from high pressure oil

c) Mind the high temperature part of the cooling system;

If the cover of the radiator is removed while the engine coolant temperature is high, steam or hot water
will be ejected, causing burns. Waiting for the temperature drop of coolant, stand in front of the radiator
cover and slowly loosen the cover to release the steam pressure before removing the cover.
d) Remove the cable from the battery before inspecting or maintaining the electrical system;

1-5
Inspection or maintenance of the electrical system without removing the cable of the battery may cause
a short circuit and damage the wiring, electrical components and electronic components of the electrical
system;
The cable on the negative terminal side (ground side) must be removed before the inspection or
maintenance work on the electrical system.
e) Mind battery liquid;
Battery fluid contains dilute sulfuric acid. Battery fluid can cause blindness when it enters the eyes, and
burns when it comes into contact with skin. Wear goggles, protective gloves long-sleeved overalls when
handling the battery;
If the eyes or skin are in contact with the battery fluid, rinse immediately with plenty of water and get
medical attention promptly.

Figure 1-6 Mind battery fluid

f) Use the specified greased items;

Use the recommended grade or the same grade of oil and grease when replenishing or replacing. The
combination of different grades of grease will result in a chemical reaction that changes the properties
of the grease and adversely affects the mechanical properties. When using a grease that is different from
the grade used in the machine, remove the original grease thoroughly before adding new grease.

Figure 1-7 Prohibition of mixing oil

g) Maintenance is prohibited when the platform is in the raised position; If there is a special demand
for maintenance, the boom and platform should have reliable support to ensure the safety and
reliability;
h) Precautions after maintenance:
1) After maintenance, the operation function must be confirmed to detect the oil leakage or
malfunction in the early stage;
2) It is necessary to confirm the machine movement, oil leakage, loose bolts and other problems

1-6
 on the mechanically maintained parts;
3) Restore or reset the safety device and recalibrate the safety device if necessary;
4) Remove the tools and equipment for maintenance, replace parts and scattered objects, and
clean up the site;
5) It should always be borne in mind that all maintenance should include mandatory
confirmation of normal mechanical movement.

1. Handle hazardous wastes according to law such as oil, fuel, filter, battery, hydraulic oil, etc.
reasonable recycling of used oil, coolant or filter element to save resources and protect the
environment;

2. It is forbidden to dump waste liquid at the sewage pipe, ground surface, river, etc. at will. The
waste liquid should be discharged into a suitable container for proper disposal;

3. The disposal of hazardous substances should be in compliance with all environmental

regulations, otherwise it will be fined or punished by relevant departments.

1-7
 SECTION 2 TECHNICAL PARAMETERS

2.1 Performance
Table 2-1 Performance

Platform capacity 300kg 661 lb

45% (platform uphill)
Max travel speed (on slope)
25% (platform downhill)
Max travel speed (side slope) 25%
Platform height 13.72m 45ft
Horizontal outreach 7.62m 25ft
4.73 m (outside) 15ft 6in (outside)
Turning radius
1.96 m (inside) 6ft 5in (outside)
Max travel speed 6.8 km/h 4.23mph
Max hydraulic system pressure 21Mpa
Max wind speed 12.5m/s (force 6 wind) 27.96mph (force 6 wind)
Max manual force 400N 90 lbs force
Electrical system pressure 12V DC
Gross weight 7250kg 15984 lb
* Stowed position

2.2 Specification and Performance

Table 2-2 Specification and performance

Turntable swing 355° non-continuous

Tail swing 0m 0in
Platform dimension 1.83 m×0.76 m 6ft×2ft 6in
Width 1.84 m 6ft
Stowed height 2.30 m 7ft 7in
Stowed length 6.68 m 21ft 11in
Wheelbase 2.36 m 7ft 9in
Ground clearance 0.42m 1ft 5in
6.8 km/h (stowed) 4.26mph (stowed)
Travel speed
0.5 km/h (working) 0.31mph (working)
Ground bearing stress 1.25MPa
Max tire capacity 3900kg 8598 lb

2-1
2.3 Capacity
Table 2-3 Capacity

Fuel tank 65 L 17.17 us gal

Hydraulic oil tank 74 L 19.55 us gal
Engine oil capacity 8L 2.11 us gal

2.4 Components Specification

2.4.1 Engine
Table 2-4 D2.9L4 (Deutz) Engine specification

Type Electric control

Fuel No. 0 National IV
Engine oil capacity About 8 L (2.11us gal)
1200rpm (idling)
Rotate speed 2000rpm (low speed)
2600rpm (high speed)
Current output of generator 14V,95A
Horsepower 49
Coolant Cold water, about 11L (2.91 us gal)

Table 2-5 D435L3 (Deutz) engine specification

Type Electric control

Fuel No.0 National IV
Engine oil capacity About 15 L (3.96 us gal)
1200rpm (idling)
Rotate speed 2000rpm (low speed)
2800rpm (high speed)
Current output of generator 14V,55A
Horsepower 49
Coolant Cold oil, about 15L (3.96 us gal)

2-2
 Table 2-6 404D-22 (Perkins) Engine specification

Type Electric control

Fuel No.0 National IV
Engine oil capacity About 8 L (2.11us gal)
1200rpm (idling)
Rotate speed 2000rpm (low speed)
2600rpm (high speed)
Current output of generator 12V, 65A
Horsepower 49
Coolant Cold water, about 11L (2.91 us gal)

2.4.2 Battery
Table 2-7 Battery specification

Rated voltage 12 V
20 hours rate capacity 90 Ah
Cold start current 750 A @ -18℃ (0ºF)
Storage capacity 160 Min @ 27℃ (80ºF)

2.5 Tire
Table 2-8 Tire size

Ply Max capacity Weight (tire and

Size Type
rating 10km/h (6.21mph) 0km/h (0mph) wheel)
315/55
Foam-filled 12 3568 kg/7866 lb 4375 kg/9645 lb 143 kg/315 lb
D20

2-3
2.6 Functional Speed
Table 2-9 Functional speed (Unit: s)

Function ZA14J
Upper boom lifting 24 s ~30 s
Upper boom lowering 24 s ~30 s
Turntable swing (a round) 60 s ~70 s
Upper boom extending 10 s ~15 s
Upper boom retracting 10 s ~15 s
Platform rotation (left an right) 10 s ~15 s
Jib lifting 25 s ~28 s
Jib lowering 24 s ~28 s
Tower boom lifting 27 s ~33 s
Tower boom lowering 24 s ~30 s
6.8 km/h (forward)/4.23mph (forward)
Travel 6.8 km/h (backward)/4.23mph (backward)
0.5 km/h (raised)/0.31mph (raised)

2.6.1 Operating procedure when testing speed

a) Upper boom lifting: telescopic boom retracting. Record lifting and descending time respectively;
b) Turntable swing: upper boom lifted to maximum work height, telescopic boom retracted. Record
360°continuous turntable swing left and right respectively;
c) Upper boom extending: upper boom lifted to maximum work height, telescopic boom retracted.
Record telescopic boom extending and retracting time respectively;
d) Jib lifting: platform leveling, chassis swing, upper boom positioned to the center of chassis. Record
lifting and descending time respectively;
e) Platform rotation: platform leveling. Platform reaches extreme position, rotate the platform to
reach the extreme position of another side, record the rotating time; rotate the platform to the
original position, record the rotating time;
f) Drive (forward/backward): select a smooth ground, position the speed switch to high speed.
Record the time of forward/reverse through 100m/328ft 1in;
g) Drive (raised): select a smooth ground, position the speed switch to low speed. Record the time of
forward/reverse through 50m/164ft 1in.

2.6.2 Test cautions

a) The stopwatch should be timed from the beginning of the actual action, not when the switch or
controller is activated;
b) Operation should be controlled by platform console when testing speed;
c) The platform speed knob should be in the full speed position;

2-4
d) The function speed may vary depending on the temperature and thickness of the hydraulic oil.
When running the test, the hydraulic oil temperature must exceed 38℃/100.4℉;
e) Some flow control functions may be disabled when the speed knob is positioned to low speed.

2.7 Torque Requirements

Table 2-10 Torque requirements

Strength grade and corresponding torque Nm

Bolt diameter
8.8 grade 10.9 grade
M8 24.5 34.5
M10 48.3 68
M12 84.3 118
M14 135 189
M16 209 294
M18 288 405
M20 408 538
M22 555 780
M24 705 992
M27 1032 1450
M30 1400 1970
Note: when maintenance is required or the fasteners are loose, follow the torque gauge to determine
the appropriate torque value.

2.8 Lubrication
2.8.1 Hydraulic oil
Table 2-11 Hydraulic oil specification

ISO viscosity grade 32

Pour point ℃/ ℉ -39/ -38.2
Flash point ℃/ ℉ 231/ 447.8
Motion viscosity cSt（40℃/104℉ ） 33.4
Viscosity index 150

2-5
2.9 Pressure Setting
Table 2-12 Pressure setting

Upper boom lifting 21MPa

Upper boom extending 21MPa
Turntable swing 12MPa
Chassis diversion 18MPa
Jib lifting 21MPa
Platform rotation 21MPa
Platform leveling 17MPa
Tower boom lifting 21MPa

2-6
 SECTION 3 GENERAL INTRODUCTION

3.1 Machine Preparation, Inspection and Maintenance

3.1.1 General introduction
This section provides the necessary information to the operator responsible for pre-operational
inspection and safe operation. In order to obtain the longest service life and ensure safe operation, all
necessary inspections and maintenance should be completed before the machine is put into use.

3.1.2 Preparation, inspection and maintenance

Comprehensive inspection and preventive maintenance programs must be developed and adhered to.
The table below describes the regular inspections and maintenance recommended by our company.
Please check the relevant national or regional regulations or local provisions to get more information
about the aerial work platform. The frequency of inspection and maintenance is increased
correspondingly for equipment that is often operated in a harsh environment or with a high frequency of
operation.

The user or operator should first perform a pre-start check before daily use or each shift change. For
detailed steps on pre-start inspection, please refer to the Operation Manual. Read and fully understand
the Operation Manual before proceeding with the pre-operation check.

3.1.3 Pre-delivery and daily inspections

Pre-delivery inspections must be performed by a qualified equipment engineer. Equipment engineers
recognized by our company should have recognized qualifications, certificates, extensive knowledge
and experience, and have received relevant training, as well as the ability and level required to repair
and maintain the products described in this manual. Pre-delivery and daily inspections are performed in
the same way, but at different times. Pre-delivery inspections must be carried out each time before being
sold, rented or leased. Every equipment used for 3 months or 150 hours (whichever comes first), or idle
for more than 3 months, or purchased as a used equipment, must be routinely inspected. The frequency
of inspection is increased correspondingly for equipment that is often operated in a adverse environment
or with a high frequency of operation. Please refer to the Pre-delivery Inspection and Daily Inspection
Form and the Preventive Maintenance Schedule for inspections. Please refer to the relevant contents of
this manual for maintenance and service procedures.

3.1.4 Machine annual inspection

The factory-certified maintenance engineer shall perform annual inspections of the machine every year
for 13 months after the date of last annual inspection. The maintenance engineer shall receive
professional training for the relevant models and pass the training test. Please refer to the Maintenance
Manual and the applicable checklist for this inspection.

Refer to the Machine Annual Inspection Form and the Preventive Maintenance Schedule for this

3-1
inspection. Please refer to the relevant contents of this manual for maintenance and service procedures.
To ensure that safety reports are obtained, our company needs to update the ownership information of
each machine. Please inform us of the current machine ownership information each time the machine
annual inspection is carried out.

3.1.5 Preventive maintenance

Equipment engineers should perform preventive maintenance in conjunction with prescribed inspections.
Equipment engineers recognized by our company should have recognized qualifications, certificates,
extensive knowledge and experience, and have received relevant training, as well as the ability and level
required to repair and maintain the products described in this manual.

Please refer to the Preventive Maintenance Schedule of this manual for maintenance and service
procedures. The frequency of maintenance is increased correspondingly for equipment that is often
operated in an adverse environment or with a high frequency of operation.

Table 3-1 Inspection and maintenance

Main Maintenance
Type Frequency Reference
responsibility certification

Operation and Safety

Pre-start Before daily use of each shift User or operator User or operator
Manual

Maintenance Manual
Ex-factory after sold, rented or Owner, dealer Qualified
Pre-delivery and the applicable
leased or user engineer
checklist

Run for 3 months or 150 hours,

Maintenance Manual
whichever comes first; idle for Owner, dealer Qualified
Daily use and the applicable
more than 3 months; or when or user engineer
checklist
purchasing a used machine

Implemented annually, within 13 Factory-certified Maintenance Manual

Annual Owner, dealer
months from the date of the last maintenance and the applicable
inspection or user
inspection engineer checklist

Preventive Follow the time intervals specified Owner, dealer Qualified

Maintenance Manual
maintenance in the Maintenance Manual or user engineer

3.2 Maintenance and Instruction

3.2.1 General description
The following information is provided to assist you in the use and application of the repair and

3-2
maintenance procedures contained in this manual.

3.2.2 Safety and operating standards

Safety is paramount when performing equipment maintenance. Always pay attention to weight. Never
attempt to move heavy parts without mechanical assistance. Do not park heavy objects in unstable
locations. Ensure that adequate support is provided when lifting.

3.2.3 Cleaning
a) Prevent dirt or impurities from entering critical parts of the machine for longer service lift. This
unit has taken preventive measures to protect against such violations. Shields, covers, seals and
filters are used to keep the air, diesel and oil supplies clean. However, maintenance should be
conducted according to the scheduled time for protective measures functioning properly;
b) When the air, diesel or oil lines are disconnected, the adjacent areas, as well as the opening and
joints, should be cleaned. Once a pipe or component is disconnected, cover all openings
immediately to prevent foreign matter from entering;
c) All parts should be cleaned and inspected during maintenance and all channels and openings
should be clear. Cover all parts to keep them clean. All parts must be cleaned before installation.
New parts should be stored in containers before use.

3.2.4 Component disassembly and installation

a) Use an adjustable lifting device if needed. All spreaders (slings, chains, etc.) must be parallel to
each other and as perpendicular as possible to the top of the hoisted part;
b) The angle between the support structure and the part is less than 90 degrees, the load capacity of
the eye bolt or similar bracket will be reduced when disassemble a part on a corner;
c) If a part is difficult to disassemble, check if all nuts, bolts, cables, brackets, and wiring have been
removed, and whether adjacent parts obstruct removal.

3.2.5 Component disassembly and reinstallation

Implement disassembling or reassembling in order. If the removal or assembly of a part has not been
completed, do not assemble or disassemble another part. Please review your work at all times to ensure
that there are no omissions, no adjustments may be made without approval (except for the proposed
adjustments).

3.2.6 Pressure-fit parts

When assembling the press-fit parts, lubricate the mating surfaces with an anti-seize type or
molybdenum disulfide-base compound.

3.2.7 Bearing
a) After removing the bearing, cover it to avoid stains or abrasives. Clean the bearing in a
non-flammable cleaning agent and allow it to drip dry. Compressed air can be used, but the

3-3
 bearings cannot be rotated;
b) If the bearing race and the steel ball (or roller) are sunken, scratched or burnt, scrap the bearing;
c) If the bearing is still serviceable, apply a layer of oil and wrap it in clean paper (or wax paper). Do
not open the reusable or new bearing packaging until you are ready to install it;
d) Lubricate the new or refurbished bearings before installation. When pressing the bearing into the
cage or bore, apply pressure to the outer bearing race. Apply pressure on the inner race when
installing the bearing on the shaft.

3.2.8 Washer
Check if holes in the washer are aligned with the opening of the fitting. Hand-made washer
should be made of washer material or stock material of the same material and thickness. Open the
hole in the correct position. Otherwise the washer will not seal properly and can seriou sly damage
the system.

3.2.9 Bolt and torque applications

a) Use bolts of the appropriate length. If the bolt is too long, the bolt will bottom out before the bolt
head is tightened onto the corresponding part. If the bolt is too short, there will not be enough
threaded parts to bite the fixed part. When replacing bolts, only bolts of the same or equivalent size
as the original bolts may be used;
b) In addition to the specific torque requirements given in this manual, standard torque values shall be
applied to heat-treated bolts, studs and steel nuts in accordance with the recommended factory
practice (see torque tables in Section 2).

3.2.10 Hydraulic line and electric wiring

When hydraulic lines and electrical wiring are removed from the equipment, they should be clearly
marked on the hydraulic lines and electrical wiring and their sockets for proper re-installation.

3.2.11 Hydraulic system

a) Keep the hydraulic system clean. If metal or rubber particles are found in the hydraulic system,
immediately drain and flush the entire system;
b) Remove or reassemble parts on a clean operating surface. Clean all metal parts with a
non-flammable cleaner. Lubricate the parts as needed to help the assembly.

3.2.12 Lubrication
Please lubricate the relevant parts at the specified intervals, use the quantity, type and grade of lubricant
recommended in this manual. If there is no recommended lubricant, consult local supplier for equivalent
lubricant that meets or exceeds the listed specifications.

3.2.13 Battery
The battery was cleaned with a non-metallic brush and an aqueous solution of sodium bicarbonate. Then

3-4
rinse with clean water. When the battery is completely dry, apply the battery terminals with an
anti-corrosion compound.

3.2.14 Lubrication and maintenance

Parts and components that require lubrication and maintenance refer to the Lubrication Table in Section
2.

3.3 Lubrication and Information

3.3.1 Hydraulic system
a) Contaminants are the primary factor in invading the hydraulic system. Contaminants can invade in
various ways, such as improper use of hydraulic oil, or the moisture, grease, metal shavings,
sealing elements, sand, etc. enter the system during maintenance, or the hydraulic pump forms
cavitation due to insufficient preheating of the system or leakage of the hydraulic pump inlet pipe;
b) The design and manufacturing tolerances of the working part of the component are very strict, so
even if a small amount of dirt or foreign matter enters the system, it may cause wear or damage to
the component and may cause operational failure. Always take precautions to keep the hydraulic
fluid clean, including stored spare oil. The hydraulic system filter is inspected, cleaned, or replaced
as necessary, at intervals specified in the Hydraulic Table in Section 2. Always check for the
presence of metal particles in the filter;
c) Turbidity of the hydraulic fluid indicates that the water content is too high, which may promote the
growth of organic matter and cause oxidation or corrosion. If this happens, the system should be
drained, flushed, and refilled with clean hydraulic fluid;
d) Other hydraulic fluids may not contain the specified additives or have different viscosities, so do
not mix products of different brands or types. It is recommended to use high quality mineral oils
with a viscosity suitable for the machine’s operating environment.

The hydraulic oil cleanliness of the machine at the factory is NAS9 (ISO4406 18/15). The normal
operation of the machine requires that the hydraulic oil cleanliness is not lower than NAS10 (ISO4406
19/16). We recommend that the hydraulic oil be inspected every 6 months. When it is time to change the
oil, at least the oil should be sampled once. The oil sample can be sent to a hydraulic oil manufacturer or
a qualified third-party testing agency for analysis and to determine if it is still available.

Note: due to the wear of the screen components, metal particles may appear in the hydraulic fluid
or filter of the new machine.

3.3.2 Hydraulic oil

For hydraulic oil types and models, please refer to Table 2-3 Hydraulic oil technical parameters (Table
3-2 is not used to specify the type and parameters of hydraulic oil). Please select the hydraulic oil of the
appropriate brand and technical parameters according to the specific use environment of the equipment.
For special environments or users with special requirements, please contact ZOOMLION or hydraulic

3-5
oil manufacturers.

Note: do not mix different brands or types of oils, and the mixing of additives in different oils will
have negative impact. If hydraulic oil mixing is unavoidable, it must be approved by the hydraulic
oil manufacturer. Our after-sales service does not take the consequence of the use of fluid mixing.

Table 3-2 Hydraulic oil technical parameter

Mobil
SHC
Kunlun Great wall
Aware H Mobil Calte
Mobil 10 Great Great 4632grease
32 Mobil DTE x Caltex
Technical DTE 10 aviation wall wall non-flammable
（environ DTE 10 10 Rand Rando
parameter Ultra hydrauli L-HV L-HV hydraulic oil N32
mental Ultra 22 Ultra o MV MV 32
32 c oil 32 46 (environmental
friendly 46 22
(ground) friendly)
hydraulic
oil）

ISO viscosity
32 22 32 46 22 32 10 32 46 32
grade

Pour -30 -54 -54 -45 -36 -36 -50 -39 -37 -20
point℃/℉ /-22 /-65.2 /-65.2 /-49 /-32.8 /-32.8 /-58 /-38.2 /-34.6 /-4
Flash 185 224/ 250 232/ 190 210 92 231/ 240 270
point℃/℉ /365 435.2 /482 449.6 /374 /410 /197.6 447.8 /464 /518
Motion
10
viscosity cSt
32 22.4 32.7 45.6 22.5 33.5 (50℃ 33.4 48.7 28.8-35.2
（40℃/104
/122℉)
℉）

Viscosity
140 164 164 164 155 155 150 150 150 180
index

Proper use of hydraulic fluid. Please note the corresponding oil viscosity and temperature limits. Under
normal operating conditions, the recommended oil temperature should be controlled between 30℃/86℉
and 60℃/140℉ and the maximum is not more than 90℃/194℉. The oil temperature will affect the
viscosity of the oil and the thickness of the oil film. High oil temperature will reduce the lubrication
effect and the life of the component. High temperatures also shorten the life of oil seals and other rubber
components, while the oil also evaporates and oxidizes.

Add the corresponding type of hydraulic oil according to the customer’s requirements before ex-factory.
When the working environment temperature changes beyond the working range of the hydraulic oil,
please replace other suitable types of hydraulic oil according to the actual situation. Considering the

3-6
safety of the components and the efficiency of the work, it is recommended that the starting temperature
of the equipment is higher than the selected hydraulic oil pour point temperature of 25℃/77℉ or more.

3.3.3 Hydraulic oil replacement

Good quality hydraulic fluids are critical to machine performance and service life. Unclean hydraulic
fluid can affect machine performance and can cause damage to parts if used continuously. This
operation should be performed more frequently in adverse working conditions.
a) Regular hydraulic fluid changes are required to use the recommended crankcase or hydraulic fluid.
Run for the first time for 50 hours, and the filter element should be replaced every 300 hours
thereafter. If the hydraulic oil has not been replaced for two years, it should be tested once every
quarter, and the hydraulic oil should be replaced if the test fails. If you need to replace the
hydraulic fluid, use a hydraulic fluid that meets or exceeds the specifications described in this
manual. If you are unable to obtain the same type of product with random hydraulic oil, please
consult your local supplier for the right equivalent. Do not mix petroleum with synthetic oil. We
recommend the hydraulic oil replacement time used by the machine as follows;
b) First replacement: run for 500 hours after debugging;
c) Second or thereafter replacement: run 2,000 hours or once every two years;
d) The above recommended values are suitable for most applications. Higher temperatures, pressures
and adverse working conditions will accelerate oil failure, so hydraulic oil should be replaced
earlier. If the system load is small, the oil change time can be extended;
e) Always take the necessary measures to keep the hydraulic oil clean. Ensure all the containers used
are clean. After replacing the hydraulic fluid of the hydraulic system, the mesh element of the filter
must be cleaned and the cartridge filter replaced;
f) After shutting down the equipment, conduct good preventive maintenance measures, that is,
implement a thorough inspection of all hydraulic components, piping, fittings, etc., and perform a
functional check of each system before reusing the machine.

3.3.4 Lubrication specification

Special lubricants recommended by the component manufacturer are always the best choice. However,
multi-purpose greases typically have characteristics that meet the requirements of various single
function greases. If you have any questions regarding the use of grease in maintenance supplies, please
consult your local supplier. Please refer to the description of the lubricant abbreviation in the
Lubrication Table in Section 2.

3.4 Cylinder Drift Test

Use the following method to determine the maximum acceptable cylinder drift.

3.4.1 Platform drift

3-7
Measure drift from the platform to the ground. Raise the lower boom slightly (if equipped) and fully
extend the upper boom with the platform capacity and power off;
The maximum allowable drift in 10 minutes is 5 cm/2 inches. If the machine fails this test, please
conduct the following operation.

3.4.2 Cylinder drift

Table 3-2 Cylinder drift

Cylinder bore size Maximum acceptable drift value in 10 minutes

Millimeter Inch Millimeter Inch

76.2 3 0.66 0.026
89 3.5 0.48 0.019
101.6 4 0.38 0.015

127 5 0.22 0.009

152.4 6 0.15 0.006

177.8 7 0.13 0.005

203.2 8 0.10 0.0038

228.6 9 0.08 0.0030

a) Use a calibrated dial gauge to measure drift on the cylinder rod. The oil in the cylinder must be in a
stable ambient temperature;
b) The cylinder must have the normal load applied by the platform;
c) If the cylinder passes this test, it is acceptable.
Note: this information is based on a leak of 6 drops of cylinder per minute.

3-8
3.5 Pin and Bearing Inspection Instructions
3.5.1 Fiber bearing
a) Disconnect and inspect the connecting pin when one of the following conditions occurs:
1) Joint tilting;
2) Noise is generated at the joint during operation.
b) Fiber bearings should be replaced in one of the following situations:
1) Wear or separate fibers on the surface of the liner;
2) Broken or damaged bearing bushing;
3) The bearing has moved or rotated into the bearing housing;
4) Debris is embedded in the surface of the bushing.
c) The pin should be replaced when one of the following conditions is found (the pin should be
properly cleaned before inspection):
1) Wear is found in the bearing area;
2) The surface of the pin has flakes or scratches;
3) The pins in the bearing area are rusty.
d) Reassemble the connecting pin with a fiber bearing.
1) The dirt and debris on the housing should be blown off. There must be no foreign objects on
the bearings and housings;
2) Bearings and pins should be cleaned with a cleaning agent to remove all grease and lubricant.
Fiber bearings do not require lubrication;
3) During installation and operation, the pins should be inspected to ensure that there are no burrs,
nicks or scratches that could damage the bearings.

3.6 Welding on the Device

Note: this instruction applies to the repair or adjustment and to the welding of external structures
or components on the machine.

3.6.1 Please perform the following operations when welding on the device
a) Disconnect the battery;
b) Disconnect the torque pin connector (when equipped);
c) Grounding only the structure being welded.

3.6.2 Do not perform the following operations when welding on the device
a) Ground the hood and weld it in any area other than the turntable;
b) Ground the turntable and weld it in any area other than the turntable;
c) Ground the platform/support and weld it in any area other than the platform/support;
d) Ground a specific boom section and weld it in any area other than the specific boom section;
e) Place pins, wear pads, wire ropes, bearings, gears, seals, valves, electrical wiring or tubing between

3-9
 the grounded location and the weld zone.

Violation of the above requirements may result in damage to components (such as electronic module,
rotating bearing, collector ring, etc.)

3.7 Use Insulating Grease in Electrical Connection Locations

Insulating silicone grease should be used for all electrical connections for the following reasons:
Prevent the mechanical joint between the male and female pins from being oxidized;
Prevent electrical failure caused by too low conductivity between pins when wet. Follow the steps
below to use insulating grease for electrical connectors. This procedure applies to all plug connections
installed outside the distribution box. Silicone grease is not suitable for use with externally sealed
connectors.
a) The silicone grease should be placed around the male and female pins on the inside of the
connector before assembly to prevent oxidation. It can be operated with a syringe for convenience;
Note: oxidation for a certain period of time will increase the resistance of the connector and
eventually cause a circuit failure.

b) Each wire that exposes the connector housing should be wrapped with silicone grease to prevent
short circuits. In addition, silicone grease should also be used at the joint where the male and
female plugs are connected to each other. Other joints (such as around the buckle) that may cause
the connector to enter the water should also be sealed;
Note: since the conductivity of the cleaning fluid is stronger than that of water, it is particularly
prone to occur when the machine is cleaned by pressure cleaning.

c) Battery boxes and battery chargers should be sealed with silicone grease.
Note: coagulating sealants can also be used to prevent short circuits and are relatively clean, but
will be more difficult to handle later when removing the pins.

3.8 Engine Electrical System Maintenance

The engine electrical system integrates a computer and microprocessor to control engine ignition, fuel
control, and emissions. Since the computer is very sensitive to good electrical connections, the electrical
wiring must be checked regularly. The following steps should be taken when checking the electrical
system:
a) Check and clean the battery terminal connections to ensure a secure connection;
b) Inspect the battery case for cracks or damage;
c) Check the positive and negative battery cables for corrosion, abrasion or scratches. Check the
connection on the chassis to confirm that the connection is secure;
d) Inspect the wiring harness of the entire engine to confirm the presence of worn, severed or

3-10
 damaged connections and repair if necessary;
e) Check all harness connectors to ensure they are fully seated and locked;
f) Check the ignition coil and spark plug cable for hardening, cracking, wear, separation, cracking of
the dust cover, and proper meshing;
g) Replace the spark plug at the time intervals specified in the engine manufacturer’s manual;
h) Check and confirm that all electrical components are securely connected;
i) Check the ground and platform control consoles to verify that all warning indicators are working
properly.

3-11
 Table 3-3 Inspection and preventive maintenance schedule

Time intervals
Items Pre-delivery Every 2
Pre-start Weekly Monthly Annually
or daily years
Boom assembly 9
Boom weldment 1,2,4 1,2,4
Oil pipe/wire rope 1,2,9,12 1,2,9,12
Shaft pin and pin 1,2 1,2
Pulley and pulley pins 1,2 1,2
Bearings 1,2 1,2
Wear pad 1,2 1,2
Covers or shields 1,2 1,2
Cables or wire 1,2,3 1,2,3
Platform assembly 9
Platform 1,2 1,2
Railing 1,2 1 1,2
Door 5 1 1,5
Floor 1,2 1 1,2
Rotary motor 9,5 15
Lanyard anchorage 2 1,2,10 1,2,10
Turntable assembly 9
Swing bearing or worm
1,2,14 1,2,3,13,14
gear

Swivel joint 9
Turntable drive system
Turntable pin 1,2,5 1,2,5
Hood, hood props and
5 1,2,5
hood latches
Chassis assembly 9
Tire 1 16.17 16,17,18 16,17,18
Wheel nuts/screw 1 15 15 15
Wheel bearing 14,24
Oscillating axle/Lockout
5,8
cylinder system
Outrigger or extendable
5,8 5,8
axle

3-12
 Table 3-3 Inspection and preventive maintenance schedule (continuous)

Time intervals
Items Pre-delivery Every 2
Pre-start Weekly Monthly Annually
or daily years
Steer components

Drive motor
Torque hub 11 11
Function/Control 9
Platform control 5 5 6 6
Ground control 5 5 6 6
Function control locks,
protective device or brake 1,5 1,5 5 5
device
Foot switch 1,5 5 5
Emergency switch (Ground
5 5 5
and platform)
Function limit or cutout
5 5
switch system
Capacity indicator 5
Drive brake 5
Swing brake 5
Boom
synchronization/sequencing 5
system
Manual descent/auxiliary
5 5
power
Power system 9
Engine idle, throttle and
3 3
RPM
Engine fluid (engine oil,
11 9,11 11 11
engine coolant, diesel oil)
Air/diesel filter 1,7 7 7
Exhaust system 1,9 9 9
Batteries 5 1,9 19
Battery fluid 11 11 11
Battery charger 5 5

3-13
 Table 3-3 Inspection and preventive maintenance schedule (continuous)

Time intervals
Items Pre-delivery Every 2
Pre-start Weekly Monthly Annually
or daily years
Fluid reservoir, cap and
11,9 2 1,5 1,5
breather
Hydraulic/Electrical system 9
Hydraulic pump 1,9 1,2,9
Hydraulic oil tank 1,9,7 2 1,2,9 1,2,9
Cylinder pinned joints and
1,9 1,2 1,2
pins retainer
Hydraulic hose and other
1,9 12 1,2,9,12 1,2,9,12
hydraulic fittings
Hydraulic oil tank, cap and
11 1,9 2 1,5 1,5 24
breather hole
Hydraulic oil filter 1,9 7 7
Hydraulic oil 11 7,11 7,11
Electrical connections 1 20 20
Instruments, meter, switch,
1 5,23
light and horn
General description
Operation and Safety
21 21 21
Manual in storage container
Equipped with ANSI and
21
EMI manual/guide
Complete and clear capacity
21 21 21
decal
Complete and clear decals 21 21 21
Visual inspection of the
21
machine appearance
Machine annual inspection
21
expires
No unauthorized changes or
21 21
additions
Consolidate all relevant
21 21
security publications
General structural state and
2,4 2,4
welding

3-14
 Table 3-3 Inspection and preventive maintenance schedule (continuous)

Time intervals
Items
Pre-delivery Every 2
Pre-start Weekly Monthly Annually
or daily years
All fasteners, pins, hood and
1,2 1,2
covering
Lubricating grease and its
22 22
specification
All system functional test 21 21 21, 22
Painting and appearance 7 7
Imprint check date on the
22
frame
Notifying Zoomlion machine
22
ownership

Footnote:
1. Before daily use or each shift
2. Before each sale, rental or delivery
3. Use 3 months or 150 hours, or idle for more than 3 months, or buy as a used machine
4. Implement inspection annually within 13 months from the date of the last inspection

3-15
 Performance code:
1 －Confirm that the installation is correct and secure
2 －Visually inspect for damage, cracks, deformation or excessive wear
3 －Check if the adjustment is correct
4 －Check for cracked or damaged welds
5 －Correct operation
6 －Return to neutral of OFF position when released
7 －Clean and free of dirt
8 －Interlock function
9 －Check for signs of leaks
10 －Complete and secure decal
11 －Level check
12 －Check for wear and correct routes
13 －Correct tolerance check
14 －Correct lubrication
15 －Reverse to appropriate torque specification
16 －No boring, excessive wear or bare rope
17 －Properly inflated and mounted to the rim
18 －Appropriately authorized parts
19 －Fully charged
20 －The joint is not loose, corroded or worn
21 －Confirmation
22 －Perform performance check
23 －Correct seal
24 －Discharge, clean, refill

3-16
 SECTION 4 CHASSIS AND TURNTABLE

4.1 Tire and wheel

The wheels consist of tires and rims.
Function: support the machine; ensure good adhesion to the road surface and transmit driving torque
and braking torque; determining the direction of travel, alleviating the impact of the vehicle on the
uneven road surface while driving, and attenuating the vibration generated thereby.

Figure 4-1 Wheel composition

4.1.1 Tire inflation

In order to endure the safety and normal operation, the air pressure of the pneumatic tire must be the
same as the air pressure indicated on the side of the Zoomlion machines or the rim sticker.

4.1.2 Tire damage

For pneumatic tires, our company recommends:
When any cuts or cracks in the tire are found to expose the sidewalls of the tire or the tread, take
immediate action to stop using our products. Also prepare to replace the tire or tire assembly.

For polyurethane foam tires, our company recommends:

Any of the following conditions are found, measures should be taken immediately to stop using our
products and prepare to replace the tires or tire assemblies.

4-1
a) A smooth, uniform cut with a total length of more than 7.5cm/3 inches in the ply;
b) Cracks (uneven edges) in any direction that exceed 2.5cm/1 inch in the ply;
c) Perforations having a diameter of more than 2.5cm/1 inch;
d) Any damage to the ply of the tire bead. If the tire is damaged but still within the above criteria, the
tire must be inspected daily to ensure that the damage does not exceed the permissible standard.

4.1.3 Tire replacement

Our company recommends replacing the tires of the same size, grade and brand as the original tires of
the machine. Please refer to our company’s parts manual for the part number of the certified tire for a
specific machine model. If you do not use our company-certified tires, the replacement tires used should
have the following characteristics:
a) Play/rated load and size equal or better than original tires;
b) The tread grounding width is equal to or better than the original tire;
c) Wheel diameter, width and compensation dimensions are equivalent to original tires.
Do not replace the foam-filled or solid-filled tire components with pneumatic tires without special
approval from our company. Ensure that all selected tires are inflated to the pressure recommended by
our company. Due to the dimensional differences between different brands of tire, the same brand
should be used for the two tires on the same axle.

4.1.4 Wheel replacement

The rims installed on each model are rigorously designed for stability requirements such as track, tire
pressure and load capacity. Unauthorized changes to the rim width, center piece position, and diameter
size without the written advice of the factory may result in an unstable hazardous situation.

4.1.5 Wheel installation

It is extremely important to use and maintain proper wheel mounting torque.

The wheel tightening nut should be mounted and held with proper torque to prevent loosening of the
wheel, damage to the stud and disengagement of the wheel from the axle. Use nuts that match the cone
angle of the wheel only. Tighten the nut to the proper torque to prevent the wheel from loosening. Use a
torque wrench to tighten the fasteners. If you do not have a torque wrench, use a socket wrench to
tighten the fasteners and then immediately ask the service station or dealer to tighten the nuts to the
correct torque. Excessive tightening will cause the stud to break or permanently deform the stud holes
on the wheel. The correct steps to tighten the wheel are as follows:
a) Manually screw all the nuts to prevent threading. Do not use lubricant on threads or nuts;
b) Please tighten the nuts in the following order:

4-2
 Figure 4-2 Wheel fastening nut tightening sequence

c) Nut tightening should be carried out in steps. Please refer to the wheel torque table and tighten the
nuts in the recommended order;

Table 4-1 Wheel torque table

Torque application sequence

First step Second step Third step

75 Nm/54.3 ft·lb 150Nm/108.5 ft·lb 260 Nm/188 ft·lb

d) The fastening nut should be tightened for the first time of 50 hours or after each disassembly of the
unit. Torque should be checked every 3 months or 150 hours of operation.

4.2 Swing axle exhaust and locking test

4.2.1 Floating cylinder exhaust
a) Start engine;
b) The turntable is in a stowed position;
c) Connecting the cleaning tube to the threaded joint of the exhaust valve;
d) Place a small bucket or bottle in front of the floating cylinder exhaust valve and insert the cleaning
tube;
e) Loosen the exhaust valve and slowly unscrew it counterclockwise. Air is exhausted from the top of
the floating cylinder. Use a small bucket or bottle to catch the hydraulic oil that flows out. Close
and tighten the exhaust valve at the same time;
f) Find the exhaust valve on the opposite side of the floating cylinder and repeat the above steps.

4-3
 Figure 4-3 Exhaust valve connector position

4.2.2 Swing axle lock test

Locking system testing must be performed quarterly when components of the locking system are
replaced or improper system operation conducted.

Note: before starting the floating cylinder test, make sure the boom is fully retracted, lowered and
centered in the middle of the two drive wheels.

a) Place a 15.2cm/6 inch block with a rising ramp in front of the left front wheel;
b) Start the engine from the working platform controller side;
c) Place the drive lever in the forward position and very carefully climb on the ascending ramp so that
the left front wheel is at the top of the block;
d) Drive the telescopic cylinder very carefully, with the boom extended at least 0.6m/2ft;
e) Position the drive lever in the reverse gear position and drive the mechanical device away from the
block and ramp;
f) Ensure that the left front wheel is locked on the ground;
g) Drive the telescopic cylinder very carefully to return the boom to the stowed position. The floating
cylinder should be released and allow the wheel to rely on the ground, and it may be necessary to
activate the system to release the cylinder;

4-4
h) Repeat the above steps to operate the right front wheel;
i) If the function of the floating cylinder is abnormal, contact the qualified personnel to correct the
malfunction, then perform other operations.

4.3 Chassis Angle Sensor System

The chassis angle sensor system is used to measure the angle of the turntable relative to the chassis. The
control system reads the sensor reading and compares the reading to a preset turntable angle value. The
turntable will be limited when the chassis rotates more than the preset value. It is necessary to manually
confirm whether the turntable is rotating in the correct direction and press the confirmation switch to
release the limit to prevent a safety accident caused by wrong operation,

4.4 Auxiliary Power System

In the event that the main power is not working, the auxiliary power system is used as an alternative to
take the operator away from the height of the work to the safe ground. This system uses an electric
motor/pump unit powered by a 12V battery. The auxiliary power system is not intended to be used as
the primary power source. The auxiliary power system allows all functional units to return to the stowed
or lowered state and supports the jib lifting. The auxiliary power system keeps the work platform in a
horizontal position when the boom is lowering. The auxiliary power system does not support the driving
function.

4.5 Oscillating axle system

The oscillating front axle is mounted to the frame by a pivot pin that allows the four wheels to remain in
contact with the ground traveling over rough terrain. The oscillating axle system also includes two
floating cylinders for connecting the frame to the front axle. The floating cylinder allows the front axle
to oscillate when the boom is retracted in transit. When the boom is extended by 569mm/22.4 inches or
the boom angle is more than 5° with respect to the horizontal level, the floating cylinder will keep the
front axle in its original position and prevent it from swinging.

The ground controller monitors the boom angle by installing an angle sensor at the end of upper boom.
The ground controller monitors the boom extension by a wire sensor mounted on the inside of the boom.
When the ground controller detects that the condition for releasing the front axle lock is satisfied, the
controller sends a pilot pressure to the floating cylinder. The pilot pressure is provided by driving the
pump charge pressure. When the pilot pressure is applied to the balancing valve mounted on the floating
cylinder, the front axle is unlocked, and when the pilot pressure is released, the front axle is locked. The
first lock compound valve is normally closed, and it opens when oil flows into the floating cylinder. The
second valve is connected to the tank and is located between the first valve and the floating cylinder. It
closes when it blocks the oil return to the tank or the oil flowing to the floating cylinder. Any of these
valves are in their normal state, the front axle should be locked. The ground control provides power and
monitors the boom angle sensor and wire sensor. If the status of the sensor is inconsistent, the ground

4-5
control will cut off the power supply, which will cause the swing front axle to lock in an unsafe state
until it is re-powered.

Figure 4-4 Floating cylinder disassembly diagram

4.6 Traveling Drive System

The traveling system is mainly composed of wheels, traveling reducer and traveling motor. Specifically,
the four-wheel drive system consists of a variable displacement closed pump, four variable
displacement piston motors, four gear reducers, and a split/flow-combining travel control valve. The
two-wheel drive system consists of a variable displacement closed pump, two variable displacement
piston motors, two gear reducers and a split/flow-combining travel control valve. The walking speed is
changed according to the three factors of driving pump displacement, engine speed and motor
displacement. Traction control is full-time full mode. Our equipment has three drive modes to choose
from at the platform console. The drive system function is determined by the position of the boom (in
the transport state or not in the transport state).

4-6
 Figure 4-5 Travel system disassembly diagram 1

Figure 4-6 Travel system disassembly diagram 2

4.7 Travel Reducer

4.7.1 Disassembly
a) Place the machine on a solid level surface;
b) Remove all hydraulic lines connected to the travel motor on the travel reducer and close the port;
c) Use a suitable lifting device to support the travel reducer. The travel reducer weighs approximately
50kg /110 lb;

4-7
d) Disassemble the six bolts used to connect the travel reducer and the chassis structure;
e) Remove the travel reducer from the equipment and place it in a clean work area.

Figure 4-7 Travel reducer disassembly diagram

4.7.2 Installation
a) Use a suitable lifting device to support the travel reducer. The travel reducer weighs approximately
50kg/110 lb;
b) Align the mounting holes on the travel reducer with the holes of the reducer mounting plate;
c) The travel reducer is mounted on the axle with six bolts, and the bolt torque is 260Nm/188 ft·lb;
d) Connect the hydraulic line that was previously disassembled to the travel motor.

4-8
4.8 Traveling Motor
4.8.1 Disassembly
a) Place the machine on a solid level surface;
b) Remove all hydraulic connections to the traveling motor and mark them;
c) Use a suitable lifting device to support the traveling motor. The traveling motor weights
approximately 15.4kg/34 lb;
d) Disassemble the two mounting bolts used to connect the traveling motor to the steering knuckle;
e) Disassemble the traveling motor from the steering knuckle and place it in a clean work area;
f) Clean the dirt on the traveling motor. Remove the rust from the output shaft.

Figure 4-8 Traveling motor disassembly diagram

4.8.2 Installation
a) Use a suitable lifting device to support the traveling motor. The traveling motor weights
approximately 15.4kg /34 lb;
b) Mounting the traveling motor on the machine;
Note: if the travel motor output shaft is not aligned, it will cause damage to the bearings and seals
of the traveling motor output shaft and its surroundings. Damage to the seal can cause oil
leakage.

c) Make sure that the traveling motor output shaft is properly aligned with the mounting ring gear on
the reducer;
d) Tighten the two bolts used to connect the travel motor to the steering knuckle. The tightening

4-9
 torque reaches 95Nm/68.7 ft·lb;
e) Reinstalling the previously removed hydraulic line connected to the traveling motor;
f) Start the unit and check the function of the traveling motor.

4.9 Generator
a) Every 250 hours;

Check that the drive belt tension is appropriate every 250 hours of operation.
b) Every 500 hours;
The generator carbon brush and slip ring should be maintained every 500 hours of operation.
More frequent maintenance may be required in adverse environments.

Use a hair dryer to blow the inside of the generator every 500 hours of operation.
If the unit used in adverse environments, it should be cleaned once a month.

c) Overload protection
When checking or maintaining the circuit breaker, stop the engine operation;
The circuit breaker provides overload protection for the generator windings. If the circuit breaker is

4-10
open, the generator will stop outputting. If the circuit breaker remains open, check the equipment
connected to the platform socket for any malfunction.

Check the carbon brush, replace the carbon brush, clean the slip ring

a) Check the carbon brush position;

Check that the carbon brush is aligned with the slip ring. Check the alignment through the air holes in
the stator. The carbon brush should be completely aligned with the slip ring.
b) Check the carbon brush;
Remove the terminal switch board. Check the wires. Remove the carbon brush holder assembly. Pull the
carbon brush off the brush holder;
If the carbon brush is damaged, or the carbon brush is at or near the minimum length, it should be
replaced immediately.
c) Check slip ring;
Visually check the slip ring. The slip ring usually turns dark brown under normal use;
If the slip ring is corroded or its surface is not flat, loosen the belt and manually rotate the shaft to clean
it;
Use 220 emery paper to clean the ring. Be as careful as possible when removing debris. If the
depression of the ring is deep and cannot be cleaned, contact the generator manufacturer’s service
personnel;
d) Reinstall the belt, brush holder assembly and terminal switch board.

4-11
 SECTION 5 BOOM AND PLATFORM

5.1 Platform and Jib

5.1.1 Load cell

5.1.1.1 Disassembly

Figure 5-1 Load cell disassembly diagram

a) Retract the tower boom and the upper boom;

b) Disconnect the wiring harness at the platform control box and the load cell, disconnect the pipeline
at the platform valve, and mark it at the same time;
c) After the hydraulic line is disconnected, the port of the pipeline should be blocked immediately to
prevent dust and other pollutants from entering the hydraulic system;
d) Remove the connecting bolts 1 and 3 of the bracket and the working platform, and use the
appropriate lifting equipment to remove the working platform from the bracket;
e) Disassemble the connecting bolts 4 and 5 of the swing cylinder and the transition seat, and remove
the bracket from the swing cylinder using suitable lifting equipment;
f) The load cell can be removed by removing the connection bolt 2 between the load cell and the
bracket or the transition seat.

5.1.1.2 Inspection
a) Check the line for wear and replace the wiring harness if necessary;
b) Check hydraulic oil leaks and replace the line if necessary;
c) Inspect all threaded parts for damage such as stretching, thread deformation or distortion and
replace if necessary.

5.1.1.3 Installation
a) Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint before

5-1
 installation should be cleaned to prevent contaminants from entering the hydraulic system;
b) Threaded fasteners should be tightened in place according to the torque values in Section 2
Specifications.

5.1.2 Rotary actuator

5.1.2.1 Disassembly

Figure 5-2 Jib lifting cylinder disassembly diagram

a) Disconnect the hydraulic line connecting the rotary actuator balancing valve, collect the hydraulic
oil in the pipeline with a suitable container, and seal the port of the pipeline after collecting;
b) Disassemble the support and the stop pin 1 of the upper boom and the connecting pin 2, and
remove the jib using a suitable lifting device;
c) Remove the connecting bolt 5 between the rotary actuator and the upper and lower links, and
remove the pin 6, then remove the rotary actuator.

5.1.2.2 Inspection
a) Check the line for wear and replace the wiring harness if necessary;
b) Check hydraulic oil leaks and replace the line if necessary;
c) Inspect all threaded parts for damage such as stretching, thread deformation or distortion and
replace if necessary.

5.1.2.3 Installation
Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint and balance valve
before installation should be cleaned to prevent contaminants from entering the hydraulic system.

5.1.3 Jib lifting cylinder

5.1.3.1 Disassembly
a) Mark and disconnect the hydraulic line connecting the jib lifting cylinder balancing valve, collect
the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after

5-2
 collecting;
b) Remove the connecting bolts 3 and 5 of the support and the upper and lower links, and remove the
pins 4 and 6, so that the jib lifting cylinder can be removed.

5.1.3.2 Inspection
a) Check the line for wear and replace the wiring harness if necessary;
b) Check hydraulic oil leaks and replace the line if necessary;
c) Inspect all threaded parts for damage such as stretching, thread deformation or distortion and
replace if necessary.

5.1.3.3 Installation
Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint and balance valve
before installation should be cleaned to prevent contaminants from entering the hydraulic system.

5.2 Boom Assembly

Extrusion hazard. If the lifting equipment fails to securely fix the removed parts, the disassembled
parts may fall and cause personal injury and equipment damage. When disassembling, personnel
must be away from nearby areas.

After the hydraulic line is disconnected, the port of the pipeline should be blocked immediately to
prevent dust and other pollutants from entering the hydraulic system.

Refer to the Pin and Bearing Inspection Instructions in the Section 3 for pin and bearing
inspection.

5-3
5.2.1 Cable

5.2.1.1 Disassembly

Figure 5-3 Cable system disassembly

a) Adjusting the boom to a fully retracted state;

b) Disconnect the pipeline from the ground control box;
c) Mark and disconnect the hydraulic lines from upper boom to the control valve. Collect the
hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after
collecting;
d) Mark and disconnect the harness of the travel switch from the side of base boom;
e) Mark and disconnect the hydraulic lines and harness from the telescopic boom to the upper
leveling cylinder, from the telescopic boom to the jib. Collect the hydraulic oil in the pipeline with
a suitable container, and seal the port of the pipeline after collecting;
f) Use suitable lifting equipment to hang the ends of the fixed pipe of the cable along the entire
length;
g) Remove the bolts 1 and 7 that fix the moving tube on the telescopic boom;
h) Disassemble the bolts 3 and 6 of the fixed bracket on base boom;
i) Take all feasible safety precautions and use the lifting equipment to lift the cable together with the
moving pipe and pallet;
j) The cable can be removed separately by removing the bolts 2 and 5.

5.2.1.2 Inspection
a) Check the line for wear and replace the wiring harness if necessary;
b) Check hydraulic oil leaks and replace the line if necessary;
c) Inspect all threaded parts for damage such as stretching, thread deformation or distortion and

5-4
 replace if necessary;
d) Check the cable structure for bending, cracking, weld separation or other damage and replace the
cable structure if necessary.

5.2.1.3 Installation
a) Follow the reverse steps of disassembly. The pipe joints of the hydraulic lines before installation
should be cleaned to prevent contaminants from entering the hydraulic system.
b) A hydraulic system pipe joint equipped with a sealing device needs to replace a sealing device
before the hydraulic line is connected;
c) Threaded fasteners should be tightened in place according to the torque values in Section 2
Specifications.

5.2.2 Leveling cylinder

5.2.2.1 Disassembly

Figure 5-4 Upper leveling cylinder disassembly diagram

a) Adjust the posture of the boom and the jib to level;

b) Mark and disconnect the hydraulic line connecting the leveling cylinder balancing valve, collect
the hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after
collecting;
c) Use the appropriate lifting equipment to lift the head of the cylinder rod of the leveling cylinder,
disassemble the pin shaft 1 and 2, and remove the jib (Follow the jib removal step);
d) Disassembling the pin 3 fixing the upper leveling cylinder on the telescopic boom;
e) With the aid of the lifting equipment, slowly and carefully remove the upper leveling cylinder from
the telescopic boom to avoid damage to the leveling cylinder and the boom;
f) Use a suitable plug to block the connector of the leveling cylinder balancing valve to prevent dust
and other pollutants from entering the oil line.

5.2.2.2 Inspection

5-5
a) Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if
necessary;
b) Inspect the inner ring of the bearing for scratches, distortion, wear or other damage and replace the
bearing if necessary;
c) Inspect all threaded parts for damage such as stretching, thread deformation or distortion and
replace if necessary.

5.2.2.3 Installation
a) Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint and balance valve
before installation should be cleaned to prevent contaminants from entering the hydraulic system;
b) A hydraulic system pipe joint equipped with a sealing device needs to replace a sealing device
before the hydraulic line is connected;
c) Threaded fasteners should be tightened in place according to the torque values in Section 2
Specifications.

5.2.3 Lower leveling cylinder and lifting cylinder

5.2.2.1 Disassembly

Figure 5-5 Lower lifting cylinder and upper boom lifting cylinder disassembly diagram

a) Follow the removal steps to disassemble the working platform, the jib and the upper leveling
cylinder;
b) Adjusting the attitude of the boom to a position where the pin 3 and the pin 4 are completely
exposed and easy to disassemble;
c) Mark and disconnect the hydraulic line connecting the two cylinders balancing valve, collect the
hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after
collecting;
d) Use suitable lifting equipment to hoist the two ends of the leveling cylinder, disassemble the pin
shaft 3 and the pin shaft 1, and remove the lower leveling cylinder;

5-6
e) Use a suitable lifting device to support the tower boom to prevent the upper boom from falling
when disassembling the other cylinder;
f) Use suitable lifting equipment to hang the two ends of the upper boom lifting cylinder, disassemble
the pin shaft 4 and the pin shaft 2 respectively, and remove the upper boom lifting cylinder;
g) Use a suitable plug to block the connector of the main leveling cylinder balancing valve to prevent
dust and other pollutants from entering the oil line.

5.2.3.2 Inspection
a) Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if
necessary;
b) Inspect the inner ring of the bearing for scratches, distortion, wear or other damage and replace the
bearing if necessary;
c) Inspect all threaded parts for damage such as stretching, thread deformation or distortion and
replace if necessary.

5.2.3.3 Installation
a) Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint and balance valve
before installation should be cleaned to prevent contaminants from entering the hydraulic system;
b) A hydraulic system pipe joint equipped with a sealing device needs to replace a sealing device
before the hydraulic line is connected;
c) Threaded fasteners should be tightened in place according to the torque values in Section 2
Specifications.

5.2.4 Upper boom

Figure 5-6 Counterweight and hood disassembly diagram

5-7
5.2.4.1 Disassembly

Figure 5-7 Upper boom disassembly diagram

a) Before disassembling the upper boom, it is necessary to disassemble working platform, jib, cable,
upper leveling cylinder, counterweight (weight about 1800kg/3968 lb) and hood, according to the
disassembly steps;
b) Fully retract the upper boom to the horizontal position;
c) Use the appropriate lifting equipment to hang the upper boom (weight about 400kg/882 lb). The
two lifting points should be symmetrically placed on both sides of the center of gravity of the
upper boom, as shown in the figure. After disassembling the pin 1, the upper boom can still be
basically horizontal or does not have large shaking and bumps other structural members;
d) Remove shaft pin 1;
e) Operate the lifting device and slowly and smoothly remove the upper boom from the device and
place it securely on a hard floor.

5.2.4.2 Inspection
a) Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if
necessary;
b) Inspect the inner ring of the bearing for scratches, distortion, wear or other damage and replace the
bearing if necessary;
c) Inspect all threaded parts for damage such as stretching, thread deformation or distortion and
replace if necessary.

5.2.4.3 Installation
a) Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint and balance valve
before installation should be cleaned to prevent contaminants from entering the hydraulic system;
b) A hydraulic system pipe joint equipped with a sealing device needs to replace a sealing device
before the hydraulic line is connected;
c) Threaded fasteners should be tightened in place according to the torque values in Section 2
Specifications.

5-8
5.2.5 Telescopic cylinder

5.2.5.1 Disassembly

Figure 5-8 Telescopic cylinder disassembly diagram

a) Need to unload the working platform, jib, cable, upper leveling cylinder, counterweight (weight
about 1800kg/3968 lb), hood and upper boom according to the disassembly steps;
b) Disassemble the hood and two stroke switches at the tail of the telescopic cylinder;
c) Mark and disconnect the hydraulic line connecting the two cylinders balancing valve, collect the
hydraulic oil in the pipeline with a suitable container, and seal the port of the pipeline after
collecting;
d) Remove the pin 1 that connects base boom to the telescopic cylinder;
e) Remove the pin 1 that connects telescopic boom to the telescopic cylinder;
f) Use a suitable lifting device and fix one end of the rope to the connecting hole on the left side of
the telescopic cylinder as shown in the figure;
g) Operate the lifting equipment, slowly and smoothly pull the telescopic cylinder out of base boom,
then hoist it on the appropriate support frame;
h) Operate the lifting device, fasten the rope to the end of the telescopic boom on the right side of the
figure, and slowly pull the telescopic boom out of the arm.

5.2.5.2 Inspection
a) Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if
necessary;
b) Inspect the inner ring of the bearing for scratches, distortion, wear or other damage and replace the
bearing if necessary;
c) Inspect all threaded parts for damage such as stretching, thread deformation or distortion and
replace if necessary.

5-9
5.2.5.3 Installation
a) Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint and balance valve
before installation should be cleaned to prevent contaminants from entering the hydraulic system;
b) A hydraulic system pipe joint equipped with a sealing device needs to replace a sealing device
before the hydraulic line is connected;
c) Threaded fasteners should be tightened in place according to the torque values in Section 2
Specifications.

5.2.6 Tower boom and its cylinder

5.2.6.1 Disassembly

Figure 5-9 Tower boom disassembly diagram

a) Need to unload the working platform, jib, cable, upper leveling cylinder, counterweight (weight
about 1800kg/3968 lb), hood and upper boom according to the disassembly steps in advance;
b) Mark and disconnect the hydraulic lines and harnesses connected to the components on the
turntable, collect the hydraulic oil in the pipeline with a suitable container, and seal the ports of the
pipeline after collection;
c) Remove the pins 1 and 2 that connect the tower boom to the turntable;
d) Use the appropriate lifting equipment to hoist the tower boom (weight about 1050kg/2315 lb). The
two lifting points should be in the symmetrical position on both sides of the center of gravity of the
tower boom as shown in the figure. After disassembling the pins 5 and 2, the tower boom can still
remain horizontal level or does not sway and bumps other structural parts;
e) Operate the lifting equipment, slowly and smoothly lift the tower boom off the turntable and place
it on a suitable support frame;

5-10
f) Lift the upper upright with lifting equipment, remove the pin 3 and 4, and hang it;
g) Lift the upper linkage with lifting equipment, remove the pin 5, and hang it;
h) Lift the tower boom cylinder with lifting equipment, remove the pin 12 and 11 and then hang it;
i) Lift the pull rod with the lifting device, remove the pin 6 and 7 and then hang it;
j) Hang the linkage with lifting equipment, remove the pin 10, and hang it;
k) Lift the lower pull rod with the lifting device, remove the pin 9 and then hang it;
l) Hang the lower pressing rod with the lifting device, remove the pin 8 and then hang it.

5.2.6.2 Inspection
a) Inspect the shaft pin for wear, scratches, taper, ovality or other damage and replace the pin if
necessary;
b) Inspect the inner ring of the bearing for scratches, distortion, wear or other damage and replace the
bearing if necessary;
c) Inspect all threaded parts for damage such as stretching, thread deformation or distortion and
replace if necessary.

5.2.6.3 Installation
a) Follow the reverse steps of disassembly. The interface of the hydraulic pipe joint and balance valve
before installation should be cleaned to prevent contaminants from entering the hydraulic system;
b) A hydraulic system pipe joint equipped with a sealing device needs to replace a sealing device
before the hydraulic line is connected;
c) Threaded fasteners should be tightened in place according to the torque values in Section 2
Specifications.

5-11
 SECTION 6 ELECTRICAL SYSTEM MAINTENANCE

6.1 Fault Code

When the unit fails, check the fault message indicated by the display on the ground console. If the
display on the ground console indicates the following fault code, remove the fault condition and restart
the device before continuing operation.

Table 6-1 Fault code list

Classification Fault code Fault code list

22001 Dtc_System_Low_Voltage
Battery
22002 Dtc_System_Over_Voltage
24021 Dtc_Canbus_Fault_Pm2gm
CAN bus 22022 Dtc_Canbus_Fault_Engine2gm
22023 Dtc_Canbus_Fault_Hmi2gm
22051 Dtc_Generator_Fault
22052 Dtc_Engine_High_Temp
Engine 22053 Dtc_Low_Oil_Pressur
22054 Dtc_Low_Fuel
22055 Dtc_Fuel_Cut_Off
14151 Dtc_Load_Sensor_Not_Standardization
14152 Dtc_Load_Cell_Comm_Error
24153 Load_Sensor_Reading_Under_Weight
11154 Dtc_Incline_Sensor_Out_Of_Range
11155 Dtc_Incline_Sensor_Comm_Erro
11156 Dtc_Incline_Sensor_Not_Standardization
Sensor
13157 Dtc_Boom_Angle_Sensor_Out_Of_Range
13158 Dtc_Boom_Angle_Sensor_Comm_Error
13159 Dtc_Boom_Angle_Sensor_Not_Standardization
22161 Dtc_Fault_Swing_Sensor
14162 Dtc_Fault_Load_Sensor_Redundancy
13163 Dtc_Boom_Angle_Singal_Redundancy
22351 Dtc_Fault_Ug_Function_Switch_Closed
24352 Dtc_Fault_Pm_Function_Switch_Closed
12353 Dtc_Fault_Ug_Main_Lift_Switch_Double_Power_On
Switch/handle 12355 Dtc_Fault_Ug_Jib_Switch_Double_Power_On
12356 Dtc_Fault_Ug_Telescope_Double_Power_On
22357 Dtc_Fault_Ug_Rotate_Switch_Double_Power_On
12358 Dtc_Fault_Ug_Leveling_Switch_Double_Power_On

6-1
 Table 6-1 Fault code list (continuous)

Classification Fault code Fault code list

22359 Dtc_Fault_Ug_Swing_Switch_Double_Power_On
22360 Dtc_Fault_Ug_Engine_Switch_Double_Power_On
14361 Dtc_Fault_Pm_Main_Lift_Joystick_Double_Power_On
14363 Dtc_Fault_Pm_Jib_Switch_Double_Power_On
14364 Dtc_Fault_Pm_Telescope_Double_Power_On
24365 Dtc_Fault_Pm_Rotate_Switch_Double_Power_On
14366 Dtc_Fault_Pm_Leveling_Switch_Double_Power_On
24367 Dtc_Fault_Pm_Swing_Joystick_Double_Power_On
24368 Dtc_Fault_Pm_Engine_Switch_Double_Power_On
14369 Dtc_Fault_Pm_Drive_Joystick_Double_Power_On
14370 Dtc_Fault_Pm_Steer_Joystick_Double_Power_On
14371 Dtc_Fault_Ug_Footswitch_Closed
14372 Dtc_Fault_Footswitch_Function
Switch/handle 14373 Dtc_Fault_Pm_Drive_Direction_Confirm_Switch
24374 Dtc_Fault_Pm_Drive_Speed_Geer_Switch
24375 Dtc_Fault_Pm_Swing_Joystick_Up_Limit
24376 Dtc_Fault_Pm_Swing_Joystick_Dn_Limit
24377 Dtc_Fault_Pm_Swing_Joystick_Medium_Offset
24378 Dtc_Fault_Pm_Main_Lift_Joystick_Up_Limit
24379 Dtc_Fault_Pm_Main_Lift_Joystick_Dn_Limit
24380 Dtc_Fault_Pm_Main_Lift_Joystick_Medium_Offset
24381 Dtc_Fault_Pm_Drive_Joystick_Up_Limit
24382 Dtc_Fault_Pm_Drive_Joystick_Dn_Limit
24383 Dtc_Fault_Pm_Drive_Joystick_Medium_Offset
24384 Dtc_Fault_Pm_Steer_Joystick_Up_Limit
24385 Dtc_Fault_Pm_Steer_Joystick_Dn_Limit
24386 Dtc_Fault_Pm_Steer_Joystick_Medium_Offset
22551 Dtc_Drive_Forward_Valve_Short_To_Ground
12552 Dtc_Drive_Forward_Valve_Short_To_Power
22553 Dtc_Drive_Forward_Valve_Open_Circuit
22554 Dtc_Drive_Reverse_Valve_Short_To_Ground
Valve 12555 Dtc_Drive_Reverse_Valve_Short_To_Power
22556 Dtc_Drive_Reverse_Valve_Open_Circuit
22557 Dtc_Drive_Forward_Valve_Feedback_Current_Fault
22558 Dtc_Drive_Reverse_Valve_Feedback_Current_Fault
21559 Dtc_Float_Control_Valve_Short_To_Ground

6-2
 Table 6-1 Fault code list (continuous)

Classification Fault code Fault code list

21560 Dtc_Float_Control_Valve_Short_To_Power
21561 Dtc_Float_Control_Valve_Open_Circuit
21562 Dtc_Brake_Valve_Short_To_Ground
11563 Dtc_Brake_Valve_Short_To_Power
21564 Dtc_Brake_Valve_Open_Circuit
21565 Dtc_2speed_Valve_Short_To_Ground
21566 Dtc_2speed_Valve_Short_To_Power
21567 Dtc_2speed_Valve_Open_Circuit
22568 Dtc_Steer_Left_Valve_Short_To_Ground
12569 Dtc_Steer_Left_Valve_Short_To_Power
22570 Dtc_Steer_Left_Valve_Open_Circuit
22571 Dtc_Steer_Right_Valve_Short_To_Ground
12572 Dtc_Steer_Right_Valve_Short_To_Power
22573 Dtc_Steer_Right_Valve_Open_Circuit
22574 Dtc_Swing_Left_Valve_Short_To_Ground
22575 Dtc_Swing_Left_Valve_Short_To_Power
22576 Dtc_Swing_Left_Valve_Open_Circuit
22577 Dtc_Swing_Right_Valve_Short_To_Ground
Valve
22578 Dtc_Swing_Right_Valve_Short_To_Power
22579 Dtc_Swing_Right_Valve_Open_Circuit
22582 Dtc_Function_Unload_Valve_Short_To_Ground
22583 Dtc_Function_Unload_Valve_Short_To_Power
22584 Dtc_Function_Unload_Valve_Open_Circuit
22585 Dtc_4select_Main_Control_Left_Valve_Short_To_Ground
22586 Dtc_4select_Main_Control_Left_Valve_Short_To_Power
22587 Dtc_4select_Main_Control_Left_Valve_Open_Circuit
22588 Dtc_4select_Main_Control_Right_Valve_Short_To_Ground
22589 Dtc_4select_Main_Control_Right_Valve_Short_To_Power
22590 Dtc_4select_Main_Control_Right_Valve_Open_Circiut
22593 Dtc_Main_Lift_Up_Valve_Short_To_Ground
12594 Dtc_Main_Lift_Up_Valve_Short_To_Power
22595 Dtc_Main_Lift_Up_Valve_Open_Circuit
22597 Dtc_Tower_Lift_Up_Valve_Short_To_Ground
12598 Dtc_Tower_Lift_Up_Valve_Short_To_Powe
22599 Dtc_Tower_Lift_Up_Valve_Open_Circuit
23601 Dtc_Telescope_Valve_Short_To_Ground

6-3
 Table 6-1 Fault code list (continuous)

Classification Fault code Fault code list

13602 Dtc_Telescope_Valve_Short_To_Power
23603 Dtc_Telescope_Valve_Open_Circui
23604 Dtc_Hand_Leveling_Valve_Short_To_Ground
13605 Dtc_Hand_Leveling_Valve_Short_To_Power
23606 Dtc_Hand_Leveling_Valve_Open_Circuit
23607 Dtc_Jib_Valve_Short_To_Ground
13608 Dtc_Jib_Valve_Short_To_Power
23609 Dtc_Jib_Valve_Open_Circuit
23610 Dtc_Main_Lift_Dn_Safe_Vavle_Short_To_Ground
13611 Dtc_Main_Lift_Dn_Safe_Valve_Short_To_Power
Valve
23612 Dtc_Main_Lift_Dn_Safe_Valve_Open_Circuit
23613 Dtc_Main_Lift_Dn_Speed_Valve_Short_To_Groun
23614 Dtc_Main_Lift_Dn_Speed_Valve_Short_To_Power
23615 Dtc_Main_Lift_Dn_Speed_Valve_Open_Circuit
23617 Dtc_Tower_Lift_Dn_Safe_Valve_Short_To_Ground
13618 Dtc_Tower_Lift_Dn_Safe_Valve_Short_To_Powe
23619 Dtc_Tower_Lift_Dn_Safe_Valve_Open_Circuit
23620 Dtc_Tower_Lift_Dn_Speed_Valve_Short_To_Ground
23621 Dtc_Tower_Lift_Dn_Speed_Valve_Short_To_Power
23622 Dtc_Tower_Lift_Dn_Speed_Valve_Open_Circuit

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6.2 Common Faults and Solutions
Table 6.2 Common faults and solutions

No. Fault Feature Fault Cause Solution

Remove the battery or replace it with a
1. Battery exhausted
new one.
2. Operation switch or
Push the operating switch or handle
handle is not returned to
back to the neutral position
neutral position
3. Emergency stop button
Engine cannot Reset emergency stop button
1 is pressed
start
4. The main power switch Turn on the main power switch on the
does not turned on turntable
5. Engine overheat Shutdown and radiating
6. Engine oil pressure
Add engine oil
excessive low
7. Low fuel level Add fuel
1. Platform overcapacity Unload platform
2. Load cell Check load cell harness or replace
Overcapacity communication fault sensor
2
alarm 1. Check platform controller fuse and
3. Platform controller fault harness
2. Replace controller
1. Chassis tilt exceeds set
Move the device to a horizontal position
angle
3 Chassis tilt alarm 2. Chassis inclination
Check inclination sensor harness or
sensor communication
replace sensor
failure
1. Main boom exceeds Operate the main boom into the range
Boom system range of motion of motion
4
fault alarm 2. Main boom angle sensor Check main boom angle sensor harness
communication fault or replace sensor

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 Table 6.2 Common faults and solutions (continuous)

No. Fault Feature Fault Cause Solution

1. Whether the
First operate the authorization switch,
authorization switch is
then operate the action
pressed

The motion 2. Motion switch damaged Replace switch

cannot be 3. Motion handle damaged Replace handle
5
executed 4. Solenoid valve wiring
Check solenoid valve wiring
normally open circuit failure
5. Solenoid valve wiring
Check solenoid valve wiring
short circuit fault
6. Solenoid valve damage Replace solenoid valve
Check CAN bus wiring and 120Ω
1. CAN bus wiring failure
6 CAN bus fault termination resistor
2. Controller failure Replace controller

1. If you encounter any equipment failure, contact Zoomlion for timely troubleshooting;

2. If there is no absolute understanding of the fault resolution, please contact Zoomlion or

Zoomlion dealers to solve it;

3. It is forbidden to open the electric control cabinet to change the wire.

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 SECTION 7 ELECTRICAL INFORMATION AND
SCHEMATIC

7.1 General Introduction

This section introduces basic electrical information and schematics for locating and correcting most
operational problems that may arise. If problems that are not listed in this section or not be corrected by
the listed solutions, occur, you should obtain authoritative technical guidance before performing
maintenance.

7.2 Multimeter Basic Operation

Various types of multimeters or Voltmeters (VOM) can be used for troubleshooting. This section lists
the schematics of commonly used digital voltmeters in several different circuit measurements. Some of
the content may not match your Volt table.

Please refer to the Voltmeter User Manual for details.

7.2.1 Grounding
Multimeter Grounding means connecting the black lead (connected to the COM, common pole, or
negative terminal) to the negative side of the power supply with an appropriate path.

7.2.2 Backside detection

Backside Detection refers to the measurement by connecting the connector contacted on the same side
of the wire, in the rear end of the connector. In this way, the circuit is turned on to obtain a reading. If
the connector is sealed, backside detection should be conducted carefully to avoid damaging the sealing
material around the wire. It is best to use probes designed specifically for this technology, especially
when operating on sealed connectors. Insert the detector into the side of the connector as much as
possible to ensure that the test can detect both ends of the connection. The connection inside the closed
connector can be detected by back detecting both sides of the connector terminal and measuring the
resistance. Prior to this, the wire should be gently pulled to verify that the wire is still connected to the
contacts and that the contacts are sealed in the connector.

7.2.3 Minimum value/maximum value

Intermittent load conditions can be measured separately using the Min/Max recording function of some
multimeters. For example, if a certain electromagnetic coil is energized only when the switch is kept
away from the coil and the multimeter, the voltage of the electromagnetic coil can be read by this
function.

7.2.4 Polarity
The predicted voltage is positive and the actual voltage or current reading is negative, indicating that the

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leads are reversed. Check the voltage prediction value, signal position, and whether the lead is properly
connected to the device under test. Also check that the lead of the COM port is grounded or the negative
signal is connected, and that the lead of the other port is connected to the positive signal.

7.2.5 Range
M = mega = 1,000,000 * (displayed number);
k = thousand = 1,000 * (displayed number);
m = milli = (displayed number) /1,000;
μ= micro = (displayed number) /1,000,000;
For example:1.2 kΩ = 1200Ω For example:50 mA = 0.05 amps.

7.2.6 Voltage measurement

Figure 7-1 Voltage measurement (direct current)

If the multimeter cannot automatically adjust the range, set the correct range (refer to the multimeter
operation manual).

Make sure the multimeter leads are securely connected.

7.2.7 Resistance measurement

Figure 7-2 Resistance measurement

7-2
a) First test the multimeter and leads by touching the two leads. The result should show a short circuit
of resistance (very low resistance);
b) The circuit power must be turned off before testing the resistor;
c) Disconnect each component from the circuit before testing;
d) If the multimeter cannot automatically adjust the range, set the correct range (refer to the
multimeter operation manual);
e) Make sure the multimeter leads are securely connected.

7.2.8 Conduction test

Figure 7-3 Conduction test

a) The multimeter needs to use a separate button to initiate the continuity test of the beep;
b) The circuit power must be turned off before testing the conduction;
c) Disconnect each component from the circuit before testing;
d) Make sure the multimeter leads are securely connected;
e) First test the multimeter and leads by touching the two leads. The multimeter should alarm and
display continuity.

7.2.9 Current measurement

Figure 7-4 Current measurement (direct current)

7-3
a) Set the expected current range of the multimeter;
b) Verify that the multimeter leads and jacket are properly connected within the current range of your
choice;
c) If the multimeter cannot automatically adjust the range, set the correct range (refer to the
multimeter operation manual);
d) Make sure the multimeter leads are securely connected.

7.3 DEUTSCH Connector

7.3.1 DT/DTP series connector assembly

A B

C D

Figure 7-5 DT/DTP contact installation

a) Pinch the crimped contact about 25mm (1 in) behind the contact cylinder;
b) Hold the connector so that the rear guard ring faces toward you;
c) Push the contacts straight into the retaining ring until you hear a slight click. Gently pull to confirm
that the connector is fully locked;
d) When all the contacts are in place, insert the wedge lock as indicated by the arrow pointing to the
external locking device. The wedge lock will snap into place immediately. The rectangular wedge
is non-directional which can be used in any direction.
Note: the socket is as shown, follow the same steps to complete the plug connection.

7-4
7.3.2 DT/DTP Series Connector Disassembly

A B

Figure 7-6 DT/DTP contact removal

a) When disassembling, use a non-toothed nose pliers or hook line to pull the wedge locker vertically;
b) Use a screwdriver to remove the retaining finger from the contact, release the retaining finger, and
gently pull the wire to remove the contact;
c) Hold the rear seal, otherwise the seal may be displaced when the contact is removed.

7.3.3 HD30/HDP20 Series Connector Assembly

A B

Figure 7-7 HD/HDP contact installation

a) Pinch the contact piece about 25 mm (1 in) after the crimping cylinder;
b) Hold the connector so that the rear guard ring faces toward you;
c) Push the contact straight into the retaining ring until the main motion stops. Gently pull to confirm

7-5
 that the connector is fully locked.

Figure 7-8 HD/HDP lock contact position

Note: for unused wire cavities, a sealing plug should be inserted to achieve complete isolation from
the environment.

7.3.4 HD30/HDP20 Series Connector Removal

A B

Figure 7-9 HD/HDP contact removal

a) With the rear insert facing the side, select the appropriate size of the insertion and removal tool to
clamp the wire of the contact to be removed;
b) Slide the tool into the cavity of the insert until the tool catches the contact and feels stressed;
c) Pull the contact wire assembly out of the connector.

7-6
 Figure 7-10 HD/HDP non-locking contact

Note: for unused wire cavities, a sealing plug should be inserted to achieve complete isolation from
the environment.

7-7
7.4 Electrical Schematics

Figure 7-11 Electrical schematics (Figure 1/6）

7-8
Figure 7-12 Electrical schematics (Figure 2/6)

7-9
 Figure 7-13 Electrical schematics (Figure 3/6)

7-10
Figure 7-14 Electrical schematics (Figure 4/6)

7-11
 Figure 7-15 Electrical schematics (Figure 5/6)

7-12
Figure 7-16 Electrical schematics (Figure 6/6)

7-13
7.5 Hydraulic Schematics

Figure 7-17 Hydraulic schematics (Figure 1/2)

7-14
Figure 7-18 Hydraulic schematics (Figure 2/2)

7-15